KR101051868B1 - Manufacturing Method of Optical Display Unit and Manufacturing System of Optical Display Unit - Google Patents

Manufacturing Method of Optical Display Unit and Manufacturing System of Optical Display Unit Download PDF

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Publication number
KR101051868B1
KR101051868B1 KR1020107019091A KR20107019091A KR101051868B1 KR 101051868 B1 KR101051868 B1 KR 101051868B1 KR 1020107019091 A KR1020107019091 A KR 1020107019091A KR 20107019091 A KR20107019091 A KR 20107019091A KR 101051868 B1 KR101051868 B1 KR 101051868B1
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South Korea
Prior art keywords
position
1st
conveyance
means
sheet product
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KR1020107019091A
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Korean (ko)
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KR20100117089A (en
Inventor
사또루 고시오
가즈오 기따다
다꾸야 나까조노
도모까즈 유라
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닛토덴코 가부시키가이샤
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Priority to JP2008017716 priority Critical
Priority to JPJP-P-2008-017716 priority
Priority to JP2009010704A priority patent/JP4737569B2/en
Priority to JPJP-P-2009-010704 priority
Application filed by 닛토덴코 가부시키가이샤 filed Critical 닛토덴코 가부시키가이샤
Priority to PCT/JP2009/051264 priority patent/WO2009096388A1/en
Publication of KR20100117089A publication Critical patent/KR20100117089A/en
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Publication of KR101051868B1 publication Critical patent/KR101051868B1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/18Handling of layers or the laminate
    • B32B38/1825Handling of layers or the laminate characterised by the control or constructional features of devices for tensioning, stretching or registration
    • B32B38/1833Positioning, e.g. registration or centering
    • GPHYSICS
    • G02OPTICS
    • G02FDEVICES OR ARRANGEMENTS, THE OPTICAL OPERATION OF WHICH IS MODIFIED BY CHANGING THE OPTICAL PROPERTIES OF THE MEDIUM OF THE DEVICES OR ARRANGEMENTS FOR THE CONTROL OF THE INTENSITY, COLOUR, PHASE, POLARISATION OR DIRECTION OF LIGHT, e.g. SWITCHING, GATING, MODULATING OR DEMODULATING; TECHNIQUES OR PROCEDURES FOR THE OPERATION THEREOF; FREQUENCY-CHANGING; NON-LINEAR OPTICS; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating, or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/1303Apparatus specially adapted to the manufacture of LCDs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • B32B2037/268Release layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2429/00Carriers for sound or information
    • B32B2429/02Records or discs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00Electrical equipment
    • B32B2457/20Displays, e.g. liquid crystal displays, plasma displays
    • B32B2457/202LCD, i.e. liquid crystal displays
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00Electrical equipment
    • B32B2457/20Displays, e.g. liquid crystal displays, plasma displays
    • B32B2457/206Organic displays, e.g. OLED
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00Handled material; Storage means
    • B65H2701/10Handled articles or webs
    • B65H2701/17Nature of material
    • B65H2701/171Physical features of handled article or web
    • B65H2701/1719Photosensitive, e.g. exposure, photographic or phosphor

Abstract

In the case of bonding the optical film to the optical display substrate, there is provided a method of manufacturing an optical display unit and a manufacturing system of the optical display unit, in which an optical film containing a defect is appropriately excluded and the accuracy of the removal can be confirmed. do. In the process of conveying a sheet | seat product, the estimated conveyance distance at the time of conveying position specifying information formed in the said sheet product from the 1st position of the conveyance upstream to the 2nd position of the conveyance downstream rather than the said 1st position, and the said 1st The measured conveyance distance is compared with the measured conveyance distance between the said 1st position and the said 2nd position obtained by detecting the said position specifying information using a detection means in each of 1st position and the said 2nd position, and the said measured conveyance distance is the said predicted conveyance distance. The conveyance process of the said sheet product is correct | amended so that it may become in the predetermined range of.

Description

Manufacturing method of optical display unit and manufacturing system of optical display unit {METHOD OF MANUFACTURING OPTICAL DISPLAY UNIT AND MANUFACTURING SYSTEM OF OPTICAL DISPLAY UNIT}

This invention relates to the manufacturing method of the optical display unit which bonded the optical film piece to the optical display board, and its manufacturing system.

The manufacturing method of Unexamined-Japanese-Patent No. 2005-37416 (patent document 1) is known. This manufacturing method cut | disconnects another optical film (for example, a polarizing plate), leaving a release film in a sheet product (henceforth this cutting method may be called a half cut), and this release film of a sheet product Maintain continuity. And it is a method of bonding an optical film to an optical display board | substrate (for example, liquid crystal panel) through an adhesive, peeling this release film.

Japanese Patent Laid-Open No. 2005-37416

In the case of said patent document 1, the fault of an optical film is detected using a detection means before a half cut, and when a fault is detected, for example, a sheet product is cut | disconnected to avoid this fault. Such a cutting method is called a skip cut or a skip cut method. In the case of employing such a skip cut method, since the sheet product is cut to avoid defects, only an optical film having no defects is bonded to the optical display substrate.

In this skip cut method, in consideration of a defect inspection apparatus, a sheet conveying apparatus, various apparatus errors in a cutting apparatus, a control error, the mechanical error which arises at the time of continuous / stop operation, etc. which comprise a manufacturing system, It is important to have a cut in the cut size so that the defect portion is reliably excluded. These errors may become large depending on long time operation states, such as 12 hours, 24 hours, etc. Therefore, in general, these errors are comprised so that a margin of 2 to 3 times of these errors may be seen and cut | disconnected. For example, in the case where the error is theoretically or experimentally assumed to be a radius of 50 mm around the defect position, in consideration of long time operation, for example, twice the error, i.e., the defect position It is the structure which cuts assuming that a fault exists in the range of radius 100mm.

However, when cutting with a margin in this way, the yield of an optical film will worsen. On the other hand, if a skip cut is made without considering this margin, there is a risk that the optical film containing the defect is bonded to the optical display unit and is leaked as a product as it is. There are also defects of a small size that cannot be seen by the defects, so it is also possible to inspect and rework the inspection apparatus after being bonded to the optical display unit, but it is necessary to work for it and the production efficiency becomes very poor. Increasing the precision in the skip cut process is desired.

In addition, it is necessary to periodically verify whether the skipcut is being executed correctly. As the verification, conventionally, marking with magic on an optical film creates a defect, detects a defect with an inspection device, executes a skip cut with a cutting device at a later stage, and verifies whether the defect is accurately excluded. It was done. However, this verification was troublesome due to the trouble of making a fault point by an operator. Moreover, since it is necessary to operate a manufacturing system for this verification, or to verify by interrupting normal operation, it was unpreferable from a viewpoint of production efficiency.

This invention is made | formed in view of said situation, When the objective is bonded an optical film to an optical display board | substrate, the optical film containing a fault is excluded suitably, and also the precision of the said exclusion can be confirmed It is providing the manufacturing method of an optical display unit, and the manufacturing system of an optical display unit.

In order to solve the said subject, as a result of earnest research, it came to complete the following this invention.

The manufacturing method of the optical display unit of this invention,

The optical film piece which has the adhesive which consists of a pressure-sensitive adhesive layer and an optical film of the predetermined shape obtained by cutting | disconnecting the long sheet | seat product which the release film was bonded to the optical film through the adhesive layer, leaving the said release film, and cut | disconnecting the said, It is a method of peeling from the said release film and bonding to an optical display board | substrate at the adhesive layer side, and manufacturing an optical display unit,

In the process of conveying the said sheet product, the estimated conveyance distance at the time of conveying position specifying information formed in the said sheet product from the 1st position of a conveyance upstream to the 2nd position of a conveyance downstream rather than the said 1st position, and the said By comparing the measured conveyance distance between the said 1st position and the said 2nd position obtained by detecting the said position specification information using a detection means in each of a 1st position and the said 2nd position,

The conveyance process of the said sheet product is correct | amended so that the said measured conveyance distance may be in the predetermined range of the said predicted conveyance distance, It is characterized by the above-mentioned.

According to this structure, the estimated conveyance distance at the time of conveying from a 1st position to a 2nd position, and the measured conveyance distance between the said 1st position and the said 2nd position obtained by detecting the said position specification information using a detection means If the measured conveyance distance is not within the predetermined range of the predicted conveyance distance, for example, the conveyance process of a sheet product can be correct | amended so that an actual conveyance distance may fall within the predetermined range of a predicted conveyance distance. That is, since conveyance control can be correct | amended by actually detecting the conveyance distance of a sheet | seat product, it can cut | disconnect with the optical film piece which has the adhesive of the predetermined shape corresponding to the optical display substrate to bond with high precision.

The position specifying information includes, for example, a laser mark by laser marking, a magic ink mark by magic marking, an ink mark by ink jet printing means, a label, a scratch, an incision, a punching hole, and the like. Moreover, when previously formed in a sheet | seat product, two-dimensional code, a label, a barcode, a line, a hole, a distance value, etc. are mentioned, for example.

The detecting means is configured according to the position specifying information, and for example, a combination of an imaging means and an image analyzing means, a photo detector, a barcode reader, a means for detecting a hole (for example, a gear), a means for detecting a distance value, and the like. Can be mentioned.

The "predetermined range" in the "predetermined range of the conveyance distance" is set according to the request of the precision of a skip cut, for example, a lower limit and an upper limit are 100 mm or less, More preferably, 50 mm or less, More preferably, It is 20 mm or less.

Moreover, in the said invention, the said prediction conveyance distance is calculated based on the detection result of the detection means in the said 1st position, and the conveyance control means with respect to the conveyance means which conveys the said sheet product.

According to this configuration, the conveying control means controls the conveying means so that the position specifying information is detected at the second position, based on the position specifying information detected at the first position. The conveyed amount in this case corresponds to the predicted conveyed distance. The conveying means conveys the sheet product according to the conveyed amount. Although this prediction conveyance distance and an actual conveyance distance become the same, as shown in the above-mentioned subject, a prediction conveyance distance and an actual conveyance distance may differ greatly, and this application improves this suitably.

Moreover, in the said invention, the said measured conveyance distance is computed based on the conveyance distance measuring means which measures the conveyance distance of the said sheet product, and the detection result of each detection means of the said 1st position and the 2nd position. .

According to this configuration, the conveyance distance of the sheet product can be measured by the conveyance distance measuring means with the detection of the position specifying information at the first position as the starting point and the detection of the position specifying information at the second position as the end point. Can be.

Moreover, in the said invention, the detection means in the said 2nd position is provided in the conveyance direction downstream or the upstream of the said cutting means.

In a half-cut process, the sheet | seat product in a cut position may be stopped and it becomes a cause which the error of a conveyance distance tends to generate | occur | produce. Therefore, by providing the detecting means at the second position either before or after the cutting means, it is possible to appropriately correct the conveying process in consideration of the conveying distance error including the influence of the half cut process.

Moreover, in one Embodiment of the said invention, the said position specifying information is previously formed in the said sheet product, and there exists a structure in which the said sheet product is wound in roll shape. The location specifying information is the same as described above. The formation part of position identification information is not specifically limited, For example, the edge part of the sheet | seat product width direction may be sufficient, and a center part may be sufficient as it.

Moreover, in one Embodiment of the said invention, there exists a structure which forms the said position specifying information in the said sheet product from the conveyance upstream rather than the said 1st position.

The means for forming the position specifying information is configured according to the type of the position specifying information, and examples thereof include laser markers, ink jet printers, magic, labelers, punching means, cutters, and the like. Moreover, even if position specification information is previously formed in the sheet product, it can be comprised so that position specification information may be newly formed in a manufacturing process. In addition, the position which forms position specification information does not need to substantially interrupt the function of the detection means in a 1st position, and may form position identification information immediately before the detection process by a detection means, You may form position specification information with respect to the position.

Moreover, in one Embodiment of the said invention, when the measured conveyance distance does not exist in the predetermined range of the said prediction conveyance distance, there exists a structure which notifies that.

According to this, when an error fluctuates, for example, for a long time driving | operation and the position specification information (sometimes called a pseudo fault) is not excluded correctly, an operator will be notified by an alarm sound, an alarm lamp, etc. You can see that it got bigger. Thereby, an operator can analyze the error variation of a manufacturing system, and can use this analysis data effectively for adjustment of an apparatus, maintenance, etc. In addition, the operator can adjust various devices to prevent the leakage of defects.

Moreover, in one Embodiment of the said invention, the said sheet product contains the fault inherent in the said adhesive layer and / or the said optical film, and cuts into the optical film piece which has the said adhesive of the said predetermined shape which excluded the said fault. There is a configuration.

According to this structure, the adhesive layer and / or optical film which a fault exists in can be skipped with high precision, and the optical film piece which has the adhesive of the predetermined shape in which the fault was excluded can be obtained suitably. In addition, when an adhesive layer and / or an optical film contain a fault, this fault can also be used as the said position specifying information.

Moreover, in one Embodiment of the said invention, before a said 1st position, the mold release film is peeled off from the said sheet product, the fault test of the said optical film and the said adhesive layer is performed, and a mold release film is continued after a fault test. There is a configuration to join the layer.

According to this structure, a release film can be removed and defect detection (inspection) of an optical film and an adhesive layer can be performed. Therefore, the defect detection (inspection) of an optical film and an adhesive layer can be performed, without having to consider the fault, such as a phase difference inherent in a mold release film, a foreign material, a scratch, etc. which adhere to or exist in a mold release film.

Moreover, another manufacturing system of the optical display unit of this invention is

The optical film piece which has the adhesive which consists of a pressure-sensitive adhesive layer and an optical film of the predetermined shape obtained by cutting | disconnecting the long sheet | seat product which the release film was bonded to the optical film through the adhesive layer, leaving the said release film, and cut | disconnecting the said, It is a system which peels from the said release film and bonds to an optical display board | substrate at the adhesive layer side, and manufactures an optical display unit,

Conveying means for conveying the sheet product;

Conveyance control means for controlling the conveying means;

In the process of conveying the said sheet product, the estimated conveyance distance at the time of conveying position specifying information formed in the said sheet product from the 1st position of a conveyance upstream to the 2nd position of a conveyance downstream rather than the said 1st position, and the said Comparison means for comparing the actual conveyance distance between the first position and the second position obtained by detecting the position specifying information by using the detection means at each of the first position and the second position,

Correction means for correcting a conveyance process of the sheet product such that the measured conveyance distance is within a predetermined range of the predicted conveyance distance;

Cutting means for cutting the sheet product into an optical film piece having an adhesive of the predetermined shape;

Peeling means which peels the optical film piece which has the said adhesive from a release film,

It is a structure which has the bonding means which bonds the optical film piece which has the said adhesive from which the said release film peeled to the optical display substrate from the adhesive layer side.

This manufacturing system cut | disconnects a sheet | seat product into the optical film piece which has the adhesive of a predetermined shape by a cutting means, and then peels a release film from the optical film piece which has an adhesive by a peeling means, and an adhesive by the bonding means It is a structure which bonds the adhesive layer side of the optical film piece which has an optical display board | substrate. And it has a conveyance means which conveys a sheet | seat product, and the conveyance control means which controls a conveyance means. Further, the comparison means includes a predicted conveyance distance when the position specifying information formed on the sheet product is conveyed from the first position on the upstream side to the second position on the downstream side of the conveyance from the first position, the first position, and the It is a function of comparing the actual conveyance distance between the said 1st position and the said 2nd position obtained by detecting the said position specification information using a detection means in each of 2nd positions. The correction means is a function of correcting the conveyance processing of the sheet product so that the measured conveyance distance is within a predetermined range of the predicted conveyance distance.

In addition, a predicted conveyance distance is calculated based on the detection result of the detection means of a 1st position, and conveyance control means with respect to the said conveyance means. In addition, an actual conveyance distance is computed based on the conveyance distance measuring means which measures the conveyance distance of a sheet product, and the detection result of each detection means of the said 1st position and a 2nd position. The conveying distance measuring means can be constituted by an encoder or the like which detects the rotation speed of a conveying means (for example, a roller pair) constituting a part of the conveying means.

Moreover, as one Embodiment of this manufacturing system, there exists a structure in which the detection means in a 2nd position is provided in the conveyance direction downstream or upstream of a cutting means.

Moreover, as one Embodiment of this manufacturing system, there exists a structure which has position specification information formation means which forms position specification information in the said sheet product from a conveyance upstream rather than a 1st position. Moreover, when the measured conveyance distance does not exist in the predetermined range of a predicted conveyance distance, there exists a structure which has the notification means which notifies the effect.

Moreover, as one Embodiment of this manufacturing system, the said sheet product contains the fault inherent in the said adhesive layer and / or the said optical film, and cuts into the optical film piece which has the said adhesive of the said predetermined shape which excluded the said fault. There is a configuration. For example, before bonding an optical film to an optical display board | substrate (for example, a liquid crystal panel) through an adhesive layer, it is preferable to comprise a defect inspection and to exclude the optical film and / or adhesive layer containing a fault. Do. Specifically, the optical device includes a detection device for detecting a defect and a defect portion obtained by skipping the sheet product by cutting means and half-cutting the sheet product by the cutting means so as to exclude the defect detected by the detection device. The structure which excludes a film and an adhesive layer is preferable.

Moreover, as one Embodiment of this manufacturing system, Peeling means which peels a release film from the said sheet product before the said 1st position,

Means for inspecting defects of the optical film and the pressure-sensitive adhesive layer after the release film is peeled off;

There exists a structure which further has a bonding means which bonds a release film to the said adhesive layer after the said fault test.

The effect of the above manufacturing system is the same as the effect of the manufacturing method mentioned above.

As an optical display substrate of this invention, the liquid crystal panel comprised by the glass substrate unit of a liquid crystal cell, an organic electroluminescent substrate, etc. are mentioned, for example.

1 is a flowchart of a method of manufacturing the optical display unit of Embodiment 1. FIG.
2 is a flowchart of a method of manufacturing the optical display unit of Embodiment 2. FIG.
3 is a diagram for explaining a manufacturing system of the first embodiment.
4 is a diagram for explaining a manufacturing system according to the second embodiment.
It is a figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. As shown in FIG.
It is a figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. As shown in FIG.
It is a figure for demonstrating the apparatus structure of the manufacturing system of Embodiment 2. As shown in FIG.
FIG. 8 is a diagram for explaining an apparatus configuration of the manufacturing system of Embodiment 2. FIG.
It is a figure for demonstrating an example of the laminated structure of a 1st, 2nd sheet product.
10 is a diagram for explaining the functional configuration of the first embodiment.
11 is a diagram for explaining a functional configuration of the second embodiment.
12 is a flowchart for explaining the operation of the first embodiment.
13 is a flowchart for explaining the operation of the second embodiment.
14 is a diagram for explaining the functional configuration of the third embodiment.
15 is a flowchart for explaining the operation of the second embodiment.
16 is a flowchart for explaining the operation of the second embodiment.
17 is a diagram for explaining a skip cut method.
It is a figure for demonstrating the accuracy confirmation of a skip cut.

(Embodiment 1)

Embodiment 1 of this invention is demonstrated below. The flowchart of the manufacturing method of the optical display unit of Embodiment 1 is shown in FIG. An example of the apparatus structure of a manufacturing system is shown in FIG. The manufacturing system of Embodiment 1 uses the 1st, 2nd inspection pre-peeling apparatus 13, 23 and the 1st, 2nd release film attachment apparatus 15, 25 among the structures of the manufacturing system of Embodiment 2 mentioned later. It is a structural example which is not equipped. Moreover, as another embodiment of the manufacturing system of Embodiment 1, the structure which is not equipped with the 1st, 2nd fault inspection apparatus 14, 24 can also be illustrated.

(Optical film)

As the optical film formed on the optical display substrate of the present invention, for example, various optical films used for liquid crystal display devices can be used, and a polarizer, a retardation film, a vision compensation film, a brightness enhancement film, and a combination of two or more of these films are laminated. Optical film is illustrated. On the surface of these films, the protective transparent film (for example, the polarizer protective film mentioned later) may be laminated | stacked. Moreover, the adhesive layer is formed in one surface of an optical film so that it may adhere to an optical display board | substrate, and the release film for protecting this adhesive layer is formed. Moreover, the surface protection film may be formed in the other surface of an optical film directly or via an adhesive layer. The specific structure of these films is mentioned later. Moreover, the said release film is peeled from the adhesive layer formed in one surface of the said optical film to which it adhere | attaches, and the said surface protection film is peeled from the said optical film with the said adhesive layer to which it adheres. Below, the optical film in which the adhesive layer was laminated may be called the optical film which has an adhesive, and also the film in which the release film (or also the surface protection film and the adhesive layer which adhere | attaches it to an optical film) was laminated | stacked is a sheet product It may be called.

(Production flow chart)

(1) 1st roll raw material preparation process (FIG. 1, S1). An elongate first sheet product is prepared as a first roll raw material. The width of the first roll raw material depends on the bonding size of the optical display substrate. As shown in FIG. 9, in the laminated structure of the 1st sheet | seat product F1, the 1st optical film F11 and the 1st release film F12 are laminated | stacked through the 1st adhesive layer F14. have. 9 also shows the laminated structure of the first sheet product having the surface protective film F13. For example, the first optical film F11 has a first polarizer F11a, a first film F11b through an adhesive layer (not shown) on one side thereof, and an adhesive layer (not shown) on the other side thereof. And the second film F11c).

The 1st, 2nd film F11b, F11c is a polarizer protective film (for example, a triacetyl cellulose film, PET film, etc.). The second film F11c is bonded to the optical display substrate surface side via the first adhesive F14 (the first release film F12 is peeled off at this time). Surface treatment can be given to 1st film F11b. As the surface treatment, for example, a hard coat treatment, an antireflection treatment, a treatment for the purpose of preventing sticking, diffusion or antiglare, and the like can be given. The 1st release film F12 is formed through the 2nd film F11c and the 1st adhesive layer F14. In addition, surface protection film F13 is formed through 1st film F11b and the adhesive layer F15. The specific structure of 1st, 2nd film F11b and F11c is mentioned later. Below, the laminated structure of a polarizer and a polarizer protective film may be called a polarizing plate.

Each process below is performed in the isolation | separation structure isolated from the factory, and the cleanliness is maintained. In particular, it is important that the cleanliness is maintained in the bonding step of bonding the optical film to the optical display unit.

(2) conveyance process (FIG. 1, S2). The first sheet product F1 is removed from the prepared first roll raw material and conveyed to the downstream side of the manufacturing system of the optical display unit of the present invention. The 1st conveying apparatus 12 which conveys the 1st sheet | seat product F1 is comprised, for example with a nip roller pair, a guide roller, a rotation drive apparatus, an accumulator apparatus A, a sensor apparatus, a control apparatus, etc. have.

(3) 1st inspection process (it corresponds to FIG. 1, S3. Defect detection process). The fault or pseudo fault of 1st sheet | seat product F1 (substantially 1st optical film F11 and 1st adhesive layer F14) is examined using the 1st fault inspection apparatus 14. As shown in FIG. As a fault inspection method here, the method of image-photographing and image-processing transmitted light and / or reflected light with respect to both surfaces of the 1st sheet | seat product F1 is mentioned, for example. When the 1st sheet product F1 contains a polarizer, the inspection polarizing film is arrange | positioned so that it may become cross nicol with the polarization axis of a 1st sheet product (it may be called 0 degree cross), and the inspection polarizing film and Method of image-processing by imaging the transmitted light which permeate | transmits 1st sheet | seat product F1 with a CCD camera, and the polarizing axis for a test | inspection to the polarization axis of a 1st sheet | seat product and a predetermined angle (for example, it is larger than 0 degree and is within 10 degrees) ), And a method of performing image processing by imaging an image of the transmitted light passing through the inspection polarizing film and the first sheet product F1 with a CCD camera. In addition, the algorithm of an image processing can apply a well-known method, for example, can detect a fault by the light and shade determination by the binarization process. The defect inspection method is not limited to the method of image capturing and image processing by the CCD camera, and a method capable of discriminating the intensity of the transmitted light, the reflected light, the wavelength change, and the like can be adopted.

The 1st fault inspection apparatus 14 is comprised, for example by area sensors, such as a CCD camera, and is provided with several lines according to the width magnitude | size with respect to the conveyance direction of the 1st sheet | seat product F1. As an area range imaged, for example, it is a conveyance direction 100 mm x width direction 100 mm = 10000 mm <2> etc., When a fault is detected by image processing analysis, the said area is fractionated. As fraction size, a conveyance direction 5 mm x width direction 5 mm = 25 mm <2> etc. are illustrated, for example. Then, defects (type, size, number) are detected by image processing analysis for each of the divided inspection areas. The positional coordinates of the detected defects are stored as the positional coordinates of the inspection area (fractionated area). That is, the absolute coordinates of each defect are not calculated, and the defect position is stored as the coordinate of the inspection area. By configuring in this way, the processing time for defect detection can be significantly shortened. The defect information constituted here is composed of, for example, the type, size, number of defects, inspection area coordinates, identification number, image data of the inspection area, and the like, and is associated with captured image data (image data before being captured). The defect information is transmitted to the first cutting device 16. In addition, by reducing the inspection area, the resolution of the defect position is increased. In addition, the image data picked up by the first defect inspection apparatus 14 may be transmitted to the control apparatus 1, and may be configured to detect defects by image analysis in the control apparatus 1 and to generate defect information.

In the image photographing and image processing method by the transmitted light, the foreign matter inside the first sheet product F1 can be detected. In the image photographing and image processing method by the reflected light, a foreign matter on the surface of the first sheet product F1 can be detected. As an image photographing and image processing method by zero degree cross, surface foreign matters, contamination, internal foreign matters, etc. can mainly be detected as a bright spot. As the image capturing and image processing method by the x degree cross, knick can be mainly detected.

The defect information obtained by the 1st defect inspection apparatus 14 is transmitted to the control apparatus 1, and is provided to the cutting method by the 1st cutting device 16 mentioned later. In this embodiment, the defect information is used to skip cut the defect. The structure and skip cut of the fault information of this embodiment are mentioned later. The defect inspection can be carried out when manufacturing the sheet product, and the defect information obtained at this time may be formed directly on the sheet product as a bar code or the like, or a separate medium (floppy (registered trademark) disk, CD-RW, etc.). The defect information can be introduced into various media, storage devices such as a hard disk, and the like, and sent to the control device 1 of the manufacturing system of the optical display unit of the present invention.

(4) 1st cutting process (FIG. 1, S4). The 1st cutting device 16 leaves the 1st release film F12, and the surface protection film F13, the adhesive layer F15, the 1st optical film F11, and the 1st adhesive layer F14 of another member are left. It is cut (half-cut) to a predetermined size. As a cutting means, a laser device, a cutter, other well-known cutting means, etc. are mentioned, for example.

The control device 1 controls the cutting timing of the first cutting device 16. When the 1st sheet product F1 is conveyed and the cutting position reaches the 1st cutting device 16, the control apparatus 1 will operate the accumulating apparatus A, and accumulate apparatus A The conveying apparatus 12 is controlled to stop subsequent conveyance. When the first sheet product F1 stops at the cutting position, the control device 1 transmits a cutting command to the first cutting device 16. Based on this command, the 1st cutting device 16 cuts (half-cuts) the 1st sheet | seat product F1. And the control apparatus 1 is comprised so that the cutting | disconnection may be avoided based on defect information (it is a cut | disconnection system of a skip cut system). Details of this operation will be described later. In addition, the yield of the 1st optical film F11 improves significantly by this. The 1st optical film F11 containing a fault is excluded by the 1st exclusion apparatus 19 mentioned later, and is comprised so that it may not adhere to liquid crystal panel W. FIG.

(5) 1st bonding process (FIG. 1, S5). The optical film which has the 1st adhesive from which the said 1st release film F12 was removed using the 1st bonding apparatus 18, removing the 1st release film F12 using the 1st peeling apparatus 17 [ Surface protection film F13 and adhesive layer F15 included] are bonded to liquid crystal panel W by the 1st adhesive layer F14. At the time of bonding, as described later, the optical film having the first adhesive and the liquid crystal panel W are sandwiched between the roll pairs 181 and 182 to be crimped.

(6) Cleaning process (FIG. 1, S6). As shown in FIG. 3, the surface of the liquid crystal panel W is cleaned by the abrasive cleaning apparatus 10 and the water cleaning apparatus 11. The washed liquid crystal panel W is conveyed to the 1st bonding apparatus 18 by the conveyance mechanism R. FIG. The conveyance mechanism R is comprised, for example with a conveyance roller, a conveyance direction switching mechanism, a rotation drive apparatus, a sensor apparatus, a control apparatus, etc. The abrasive | cleaning washing apparatus 10 and the water washing | cleaning apparatus 11 are mentioned later.

It is preferable that each of these 1st roll raw material preparation process, a 1st inspection process, a 1st cutting process, a 1st optical film bonding process, and a washing process is performed in a continuous manufacturing line. In the above series of manufacturing processes, the optical film which has a 1st adhesive on one surface of liquid crystal panel W was bonded. The code | symbol of the liquid crystal panel in which the 1st optical film F11 was formed in one surface is shown by W1. Below, the manufacturing process which forms the 2nd optical film F21 on the other surface is demonstrated.

(7) 2nd roll raw material preparation process (FIG. 1, S11). The long second sheet product F2 is prepared as a second roll raw material. As shown in FIG. 9, although the laminated structure of 2nd sheet product F2 is a structure similar to a 1st sheet product, it is not limited to this. As for 2nd sheet product F2, 2nd optical film F21 and 2nd release film F22 are laminated | stacked through 2nd adhesive layer F24. In FIG. 9, the laminated structure of the 2nd sheet product which further has surface protection film F23 is shown. For example, it has surface protection film F23. The second optical film F21 has a second polarizer 21a, a third film F21b through an adhesive layer (not shown) on one side thereof, and an adhesive layer (not shown) on the other side thereof. It consists of the 4th film F21c through.

3rd, 4th film F21b, F21c is a polarizer protective film (for example, a triacetyl cellulose film, PET film, etc.). The fourth film F21c is bonded to the optical display substrate surface side via the second pressure sensitive adhesive layer F24 (the second release film F22 is peeled off at this time). Surface treatment can be given to 3rd film F21b. As the surface treatment, for example, a hard coat treatment, an antireflection treatment, a treatment for the purpose of preventing sticking, diffusion or antiglare, and the like can be given. The second release film F22 is formed through the fourth film F21c and the second pressure sensitive adhesive layer F24. In addition, surface protection film F23 is formed through 3rd film F21b and the adhesive layer F25. The specific structure of 3rd, 4th film F21b and F21c is mentioned later.

(8) conveyance process (FIG. 1, S12). The second sheet product F2 is removed from the prepared second roll raw material and conveyed to the downstream side of the manufacturing system of the optical display unit of the present invention. The 2nd conveying apparatus 22 which conveys a 2nd sheet product is comprised, for example with a nip roller pair, a guide roller, a rotation drive apparatus, an accumulator apparatus A, a sensor apparatus, a control apparatus, etc.

(9) 2nd inspection process (it corresponds to FIG. 1, S13. Defect detection process). The fault or pseudo fault of the second sheet product F2 (substantially the second optical film F21 and the second pressure sensitive adhesive layer F24) is inspected using the second fault inspection device 24. The defect inspection method here is the same as the method by the 1st defect inspection apparatus 14 mentioned above.

(10) 2nd cutting process (FIG. 1, S14). The 2nd cutting device 26 leaves the 2nd release film F22, and the surface protection film F23, the adhesive layer F25, the 2nd optical film F21, and the 2nd adhesive layer F24 of another member are left. It is cut (half-cut) to a predetermined size. Cutting timing is controlled by the control apparatus 1, and it is comprised so that it may cut | disconnect avoiding a fault based on the information of the fault obtained by the 2nd defect inspection apparatus 24. FIG. Thereby, the yield of the 2nd optical film F21 improves significantly. The 2nd optical film F21 containing a fault is excluded by the 2nd exclusion apparatus 29 mentioned later, and is comprised so that it may not adhere to liquid crystal panel W1.

(11) 2nd bonding process (FIG. 1, S15). Subsequently, after the 2nd cutting process, the 2nd release film F22 is removed using the 2nd bonding apparatus 28, removing the 2nd release film F22 using the 2nd peeling apparatus 27. FIG. The first optical film F11 of the liquid crystal panel W1 by the 2nd adhesive layer F24 by using the 2nd adhesive layer F24 with the optical film (including surface protection film F23 and adhesive layer F25) which has the 2nd adhesive made into it It joins to the surface which is joined to another surface. In addition, before bonding the optical film (including the 2nd optical film F21) which has a 2nd adhesive agent to the liquid crystal panel W1, the liquid crystal panel W1 is moved by the conveyance direction switching mechanism of the conveyance mechanism R. FIG. It rotates 90 degrees and may make the 1st optical film F11 and the 2nd optical film F21 into cross nicol relationship. At the time of bonding, as described later, the optical film having the second pressure sensitive adhesive and the liquid crystal panel W1 are sandwiched in a roll and pressed together.

(12) Inspection process (FIG. 1, S16). The inspection apparatus 30 inspects the liquid crystal panel W12 in which the optical film is attached to both surfaces. As an inspection method, the method of image pick-up and image processing by reflected light is illustrated about both surfaces of liquid crystal panel W12. Moreover, as another inspection method, the method of irradiating a light source from one side of liquid crystal panel W12 and image-transmitting and image-processing the transmitted light image by the transmitted light from the other side is illustrated. In this case, a fault is detected as a bright point. Moreover, as another method, the method of forming an inspection polarizing film between a CCD camera and an inspection object is also illustrated. In addition, the algorithm of an image processing can apply a well-known method, for example, can detect a fault by the light and shade determination by the binarization process.

(13) Good quality judgment of liquid crystal panel W12 is made based on the fault information obtained by the test | inspection apparatus 30. FIG. The quality-determined liquid crystal panel W12 is conveyed to the next mounting process. In the case of a defective product determination, a rework process is performed, and an optical film is newly attached and subsequently inspected, and in the case of a good product determination, the process proceeds to a mounting process, and in the case of a defective product determination, the process is reworked or discarded. do.

In the above series of manufacturing processes, the optical display unit is performed by performing the first bonding step of the liquid crystal panel and the first optical film F11 and the second bonding step of the second optical film F21 in a continuous production line. Can be prepared as appropriate. In particular, by performing the above steps inside an isolation structure separated from the factory, the optical film can be bonded to the liquid crystal panel (optical display substrate) in an environment where cleanliness is ensured, and a high quality optical display unit can be manufactured. .

(Skip cut method, skip cut accuracy confirmation processing)

The skip cut method and the confirmation processing of the skip cut precision of the first embodiment will be described. 10 is a system configuration for skip cut confirmation in the first embodiment. 12 is a flowchart of the confirmation processing of skip cut precision. Here, the example which uses the defect inspection apparatus which detects the fault of a sheet product together as an apparatus which detects the position specifying information (sometimes called a pseudo fault) formed in the sheet product for the confirmation of a skip cut precision is shown. have. Depending on the type of the position specifying information, it may be detected by the position specifying information detecting apparatus provided separately from the defect inspection apparatus.

The control apparatus 1 calculates an image analysis means 301, a memory 303, a comparison means 304, a correction means 305, a conveyance control means 306, a measured conveyance distance calculation means 307, and a predicted conveyance distance calculation. Means 308 and the like.

The conveyance control means 306 is a function of controlling the conveying apparatus 12. The image analysis means 301 analyzes the image data from the first defect inspection apparatus 14 and the imaging means 202, and calculates the kind of the defect, the coordinate position of the sheet product, the coordinate position of the pseudo defect, and the like. to be. Various data are stored in the memory 303, and the measurement data of the encoder 302 which measures the rotation amount of the conveying means 12b which comprises a part of conveyance means of the sheet | seat product F1, for example is memorize | stored. The conveying means 12b is comprised by a pair or several roll pair, and is a structure which sends out, sandwiching the sheet | seat product F1. The conveying means 12b is also controlled by the conveyance control means 306.

The measured conveyance distance calculation means 307 is a position where the pseudo defect is detected again by the imaging means 202 from the position (first position) where the pseudo defect is detected by the first defect inspection apparatus 14 (the second position). The conveyance amount measured by the encoder 302 up to the position) is calculated. This conveyance amount corresponds to the measured conveyance distance. For example, when the measurement of the encoder 302 is started from the time when the pseudo defect is detected at the first position, and the measurement is finished at the time when the pseudo defect is detected again at the second position, the encoder ( The measured amount of 302 is calculated | required as an actual conveyance distance. In addition, the encoder 302 may always be in a measurement state and may calculate by subtracting the measured value of the time when a pseudo defect was detected in a 1st position from the measured value of the time when a pseudo defect was detected in a 2nd position.

The predicted conveyance distance calculating means 308 is a position (second position) where the pseudo defect is detected again by the imaging means 202 from the position (first position) where the pseudo defect is detected by the first defect inspection apparatus 14. The estimated conveyance amount up to the position) is calculated. This conveyance amount corresponds to a predicted conveyance distance. For example, this conveyance amount is set from experience values, such as test operation and actual operation. Based on this conveyance amount, the conveying means 12b is controlled.

The comparison means 304 is a function which compares the said prediction conveyance distance with the said actual conveyance distance, and determines whether an actual conveyance distance exists in the predetermined range of a prediction conveyance distance.

The correction means 305 is a function of correcting the conveyance processing of the sheet product so that the measured conveyance distance is within a predetermined range of the predicted conveyance distance. The correction means 305 corrects the measurement function of the encoder, for example. This correction process may be performed automatically or may be performed by an operator's input operation.

It demonstrates using the operation flow of FIG. First, it is determined whether or not the accuracy of the skip cut is confirmed (S40). As a timing which gives a pseudo fault, the arbitrary time etc. which are trying to confirm the precision of a fault cutting | disconnection at the time of maintenance, in the case of performing it regularly during manufacture at the time of adjustment before manufacture start, etc. are mentioned, for example. This timing may be set previously or the structure which sets a timing arbitrarily by a manual switch may be sufficient. In this way, the pseudo defects can be markedly automatically or manually using a manual switch as compared with the conventional configuration of marking the faults directly with magic.

Marking process (position specific information formation process) (S41). As shown in FIG. 10, on the conveyance upstream of the defect inspection apparatus 14, a pseudo fault is given using the position specifying information formation means 201. FIG. In addition, at the time of manufacture of a sheet product, predetermined | prescribed pseudo defects may be previously given to a sheet product, and the sheet product to which the pseudo defect was provided can also be provided to the manufacturing system of the optical display unit of this invention. In this case, the position specifying information forming means 201 can be omitted in the system of the present invention.

Subsequently, pseudo defects marked on the first sheet product F1 are detected by the defect inspection apparatus 14 (S42). By this detection, the 1st sheet | seat product F1 is conveyed by the conveying means 12b to the conveyance direction downstream side. At this time, the encoder 302 measures the rotation amount (conveying amount) of the conveying means 12b, and the measurement data is recorded in the memory 303.

The first sheet product F1 given the pseudo fault is conveyed to the downstream side. And based on the skip cut control instruction by the control apparatus 1, the conveying apparatus 12 and the cutting device 16 are controlled, and the 1st sheet | seat product F1 containing a pseudo fault is skip cut-processed ( S44). The pseudo fault which the skip cut process was performed is detected by the imaging means 202 provided in the conveyance direction downstream of the cutting device 16 (S45). The measurement conveyance distance is calculated by this detection (S46).

Subsequently, it is determined whether the measured conveyance distance is within a predetermined range of the predicted conveyance distance (S47). If the measured conveyance distance is within a predetermined range of the predicted conveyance distance, the process returns to step S40, otherwise, a correction process is performed (S48).

Next, the skip cut method and the check processing of the skip cut precision in the second embodiment will be described. 11 is a system configuration for skip cut confirmation. 13 is a flowchart of the confirmation processing of skip cut precision. The configuration similar to that of the first embodiment will be omitted or simply explained. In the second embodiment, the imaging means 202 is provided on the conveying direction upstream side of the cutting device 16.

It demonstrates using the operation flow of FIG. First, it is determined whether or not the accuracy of the skip cut is confirmed (S40). Subsequently, as illustrated in FIG. 11, pseudo defects are provided on the conveyance upstream side of the defect inspection apparatus 14 by using the position specifying information forming means 201 (S41).

Subsequently, pseudo defects marked on the first sheet product F1 are detected by the defect inspection apparatus 14 (S42). By this detection, the 1st sheet | seat product F1 is conveyed by the conveying means 12b to the conveyance direction downstream side. At this time, the encoder 302 measures the rotation amount (conveying amount) of the conveying means 12b, and the measurement data is recorded in the memory 303.

The first sheet product F1 given the pseudo fault is conveyed to the downstream side, and the pseudo fault is detected by the imaging means 202 provided on the conveying direction upstream side of the cutting device 16 (S50). The measurement conveyance distance is calculated by this detection (S51).

Subsequently, it is determined whether the measured conveyance distance is within a predetermined range of the predicted conveyance distance (S52). If the measured conveyance distance is within a predetermined range of the predicted conveyance distance, the flow returns to step S40, otherwise, a correction process is performed (S53).

Next, the skip cut method and the process of confirming the skip cut precision in the third embodiment will be described. 14 is a system configuration for skip cut confirmation. 15 and 16 are flowcharts of the confirmation processing of skip cut accuracy.

First, it is determined whether or not the predetermined timing (S100). Timing for imparting pseudo defects is the same as that of the first embodiment.

Marking process (position specific information formation process) (S101). If it is predetermined timing S100, a pseudo fault will be provided before the said fault detection (1st, 2nd inspection process). Although the formation method of a pseudo fault is not restrict | limited, It is preferable to be given to the laser apparatus from a viewpoint of the magnitude | size of the defect of a pseudo defect, the magnitude | size of which member, etc. are formed, and a position control. The laser output can be changed depending on the member of the sheet product, and pseudo defects can be created in the surface position of the sheet product (first and second sheet products), inside the lamination, and the like. In addition, the pseudo fault can form what was illustrated as the above-mentioned position specifying information in the sheet | seat product by the formation means of the above-mentioned position specifying information, respectively.

After the marking step, the pseudo defect portion marked on the sheet product (first sheet product F1, second sheet product F2) is detected (inspected) for defects (S102). Defect detection by the defect inspection apparatuses 14 and 24 is carried out. Subsequently, sheet products F1 and F2 are conveyed to the cutting devices 16 and 26, and cutting process is performed so that a pseudo fault part may be excluded (S103). That is, pseudo defects are detected by the defect inspection apparatuses 14 and 24, defect information (information of pseudo defects) from the defect inspection apparatuses 14 and 24 is transmitted to the control apparatus 1, and the control apparatus 1 The cutting process is performed by cutting timing control by (). The cutting devices 16 and 26 cut | disconnect sheet product F1, F2 so that a fault may be excluded based on this defect information. Specifically, it cuts as follows.

The manufacturing system shown in FIG. 14 carries out the 1st conveying apparatus 12 and pseudo defect which convey 1st sheet product F1 (including the 1st optical film F11) from the upstream side of a conveyance direction to a downstream side. The imaging device 202 (CCD camera) which image | photographs the marking apparatus 201 to create, the 1st defect inspection apparatus 14 which examines a pseudo fault, the cutting device which cuts a sheet product, and the cut | disconnected 1st sheet product F1. ), The pseudo defect detection means 203 (one function of the control apparatus 1) and the 1st defect inspection apparatus 14 which analyze the imaging (image) data image | photographed by the imaging means 202, and detect a pseudo defect. The positional information determining means 204 (one function of the control apparatus 1), which determines whether the positional information of the pseudo defect detected in the coincidence with the positional information given by the marking apparatus 201, and their positional information match If not, the cutting position correction number to correct the cutting position so that their position information matches It is comprised with the stage 205 (it is a function of the control apparatus 1, and it is corresponded to a correction means).

In the marking apparatus 201, for example, pseudo defects are given at regular intervals or arbitrarily, and the pseudo defects are detected by the first defect inspection apparatus 14.

The first sheet product F1 is conveyed to the first cutting device 16 by the first conveying device 12. The 1st cutting device 16 is a structure which stops and cut | disconnects the 1st sheet | seat product F1, Therefore, the accumulating apparatus A is provided in the front end of the 1st cutting device 16. As shown in FIG. By this accumulating apparatus A, said inspection process can be performed without stopping conveyance of the 1st sheet | seat product F1. The first cutting device 16 is controlled to cut the first sheet product to a predetermined length. Then, the positional relationship between the pseudo defect position (inspection area coordinate) included in the transmitted defect information and the next cutting position is determined and cut. It demonstrates using FIG.

It is a figure for demonstrating an example of the skip cut performed in continuous operation. As shown in FIG. 17, the elongate first sheet product F1 is cut into a predetermined length a. This predetermined length a is set according to the bonding size to a liquid crystal panel (optical display substrate).

(A) If a fault or pseudo fault exists more than 100 mm in a conveyance direction upstream from a next cutting position (broken line), it cuts as a good product. That is, it is cut at the next cutting position (broken line). And in order to exclude a fault or pseudo fault, it cut | disconnects in the position of 100 mm upstream of a conveyance direction from a fault or pseudo fault (shown by a dashed-dotted line). "100 mm" used as a cutting distance from a fault or pseudo fault is previously set according to various apparatus errors, a long time driving error, a margin value, and the like. In this invention, since the clearance value does not need to be considered or a clearance value is made small, the cutting distance from a fault or pseudo fault is set small, and it is comprised so that a defect cutting precision can be confirmed regularly, and the yield of an optical film is good. Moreover, there is no danger that the optical film which has a 1st adhesive containing a fault or pseudo fault is bonded by the liquid crystal panel W, even if a margin value is not considered.

(B) If a fault or pseudo fault exists within 100 mm of a conveyance direction upstream from a next cutting position (broken line), it will cut as a defective product. It is not cut | disconnected at the next cut | disconnected position (broken line), but is cut | disconnected at the position of 100 mm of conveyance direction upstream from a fault or pseudo fault (shown by a dashed-dotted line).

(C) If a fault or pseudo fault exists more than 100 mm downstream of a conveyance direction from a next cut position (broken line), it will cut as a defective article. That is, it is not cut | disconnected at the next cutting position (broken line), and is cut | disconnected at the position of 100 mm from a defect or pseudo defect upstream to a conveyance direction in order to exclude a fault or pseudo defect (shown with a dashed-dotted line).

(D) If a fault or pseudo fault exists within 100 mm downstream of a next cutting position (broken line) in the conveying direction, it is cut as a defective product. It is not cut | disconnected at the next cutting position (broken line), but is cut | disconnected at the position of 100 mm from a fault or pseudo fault to the conveyance direction upstream (shown by a dashed-dotted line).

Subsequently, a process of analyzing the cut sheet-containing sheet product will be described.

Imaging process (S104). The first sheet product F1 including the cut pseudo defects is imaged. Similarly to the first defect inspection apparatus 14, the imaging means 202 is configured by a rear sensor such as a CCD camera, and the captured imaging (image) data is transmitted to the control device 1.

Pseudo defect detection process (S105). The pseudo fault detection means 203 which is one function of the control apparatus 1 image-processes and analyzes imaging (image) data, and detects a pseudo fault. The detection method and detection accuracy are the same as that of the fault detection by the 1st fault inspection apparatus 14.

Positional information determination process (S106). The position information determination means 204 (corresponding to the comparison means), which is one function of the control device 1, determines whether the position information of the detected pseudo defect matches the position information of the pseudo defect provided to the marking apparatus 201. Judge. For example, the image data (fragmented inspection area image data) of the pseudo defect detected by the pseudo defect detection means 203, the inspection area coordinates, and the image data of the defect information detected by the 1st defect inspection apparatus 14, for example. (The divided inspection area image data) and the inspection area coordinates are compared to determine whether they match. If they match, the flow returns to step S100 to wait for an instruction to confirm the next accuracy. On the other hand, when they do not match, in order to perform the correction process of a cutting position, in order to prevent the risk that a fault or a pseudo fault flows downstream, it progresses to a next step.

Cutting position correction process (S107). The cutting position correcting means 205 (corresponding to the correcting means), which is one function of the control device 1, corrects the cutting position so that their positional information coincides. That is, the 1st cutting device 16 so that the image data of the pseudo defect detected by the pseudo defect detection means 203, and its inspection area coordinates, and the image data of the defect information detected by the defect inspection apparatus, and its inspection area coordinates may correspond. ) To correct the cutting position. For example, as a result of image analysis, the position of the pseudo defect detected by the pseudo defect detection means 203 shifts two areas (for example, 5 mm x 2 = 10 mm in a conveyance direction) in the inspection area range downstream. If so, the cutting timing is changed to be 10 mm corrected upstream. Thereby, it is comprised so that the image data of the pseudo defect detected by the pseudo defect detection means 203, and its inspection area coordinates, and the image data of the defect information detected by the defect inspection apparatus, and the inspection area coordinates may correspond, and are faulty or pseudo It is possible to accurately exclude an optical film having a pressure-sensitive adhesive containing a defect. According to the above operation | movement, when the bonding process of the optical film which has an adhesive and an optical display board is performed continuously, it becomes possible to perform defect removal automatically with high precision.

In addition, since the shift | offset | difference of the said pseudo fault position may generate | occur | produce in proportion to the long time operation of each apparatus, the control apparatus 1 memorizes the shift amount per operation time, and if a tendency is determined, the shift amount will automatically be set for every operation time. Intelligent control to be corrected can be executed.

As another embodiment, in place of or in addition to the cutting position correcting step, a notification device such as a warning sound, a warning sound, an alarm lamp lighting / flashing, a warning display, or the like when the pseudo defect positions thereof do not coincide (not shown) There exists a structure provided with the notification process by FIG. 16 (FIG. 16, S207).

(Embodiment of the precision confirmation)

The following operations are exemplified in the case of confirming the accuracy of the defect detecting apparatus, the conveying apparatus, the cutting apparatus, the control apparatus and the like. First, the marking device 201 is provided with pseudo defects at regular intervals or arbitrarily, for example, and the pseudo defects are detected by the first defect inspection apparatus 14. It is preferable that a fault is provided to a surface and can be visually recognized also. The inspection area range of the 1st fault inspection apparatus 14 is set to the film conveyance direction 5mm x film width direction 5mm = 25mm <2>, for example. The information on the pseudo defect includes, for example, the type, size, number, inspection area coordinates, identification number, image data of the inspection area, and the like of the pseudo defect, and is associated with the image data captured by the first defect inspection device 14. do. Information of the pseudo defect is transmitted to the control device 1.

The control apparatus 1 instructs the cutting timing to the 1st cutting device 16 similarly to the said operation | movement. This cutting timing is set so that the pseudo fault part can confirm the precision of a cutting process correctly. For example, it is the setting cut | disconnected by the distance of 100 mm in a conveyance direction upstream, and a 100 mm downstream direction centering on a fault position. According to this, in theory, the pseudo fault detected by the said 1st fault inspection apparatus 14 is the center position (position of length 100mm) of the 1st sheet | seat product F1 cut | disconnected to length 200mm in a conveyance direction. It is assumed to exist in. However, due to various device errors, control errors, and the like, it is expected that the pseudo defect position exists out of the center position of the conveyance direction length of the first sheet product F1. This embodiment is a structure which can measure this shift amount, can confirm the precision of a skip cut, and correct | amends a cutting position so that a shift amount may be suppressed to a fixed range.

According to the third embodiment, the first sheet product F1 cut into a 200 mm length (corresponding to F in FIG. 18) in the conveying direction is picked up by the imaging means 202, and the pseudo defect detection means 203 is used. Image processing and analysis are performed to detect pseudo defects. In addition, when the defect can be visually recognized, the visual recognition of the cut | disconnected 1st sheet product F1 is carried out, and it can easily confirm whether a pseudo defect is located in the center with respect to the conveyance direction of the 1st sheet product F1. Can be. In this embodiment, it is the structure which the imaging means 202 image | photographs the cut | disconnected 1st sheet product F1, can analyze, and can detect a pseudo fault automatically. And the pseudo fault detection means 203 measures the distance between the center part of the detected pseudo fault, and the cut surface (end part) of a conveyance direction. If the measured distance (corresponding to the lengths L1 and L2 in FIG. 18) is in the range of 40% to 60% of the length 200 mm of the cut first sheet product F1, the first sheet product F1 in which pseudo defects are cut. And the positional information of the detected pseudo-defect coincides with the positional information of the pseudo-defect given to the marking apparatus 201. Said "range of 40%-60% of 200 mm" is an example, It can change according to the structure of a device system, conveyance distance, an inspection area area, etc., for example, 45%-55%, 30%-70% Can also be set.

On the other hand, when the measured distance is not in the range of 40% to 60% of 200 mm, the pseudo defect is detected because it is not present in the center portion of the skip cut of the cut first sheet product F1. Is determined so as to determine that the position information of? Does not coincide with the position information of pseudo defects provided to the marking apparatus 201. Then, the cutting position is corrected (correction of the cutting timing) as described above. In FIG. 18, when L1 is 45% of F length, it is determined that a fault or a pseudo fault is in the conveyance direction center part of a sheet (it does not shift | deviate). When L2 is 70% of the length, it is determined that no defects or pseudo defects are present in the conveying direction center of the sheet (deviated).

The control device 1 may be realized by a cooperative action of a software program and hardware resources such as a CPU and a memory. In this case, program software, processing procedures, various settings, and the like are stored in advance in the memory. In addition, the control apparatus 1 can be comprised with the exclusive circuit, firmware, etc. Moreover, the control apparatus 1 is comprised by the some computer (a concept including a personal computer and a microcomputer), and each said computer is a fault test apparatus 14, 24, the cutting devices 16, 26, and a conveying apparatus ( 12, 22, accumulator A, etc. may be provided.

According to the above embodiment, it is possible to periodically verify whether or not the skip cut is executed correctly. In addition, a defect part is reliably excluded in consideration of manufacturing systems, for example, a defect inspection apparatus, a conveyance apparatus of an optical film, various apparatus errors in a cutting apparatus, a control error, the mechanical error which arises at the time of continuous / stop operation, etc. can do. In addition, even if an error fluctuates, for example, due to long time operation or the like, the cutting position is automatically corrected, so that there is no fear that the optical film that does not contain defects is redundantly eliminated, and the yield of the optical film is greatly improved. Can be.

In addition, when a notification process is provided, for example, when an error fluctuates due to long time operation or the like and a pseudo defect is not accurately excluded, an error is increased to notify an operator by an alarm sound, an alarm lamp, or the like. Able to know. Thereby, an operator can analyze the error variation of a manufacturing system, and can use this analysis data effectively for adjustment of an apparatus, maintenance, etc.

Although the marking process was performed in the manufacturing system in the above-mentioned first to third embodiments, the present invention is not particularly limited thereto. For example, in the roll raw material manufacturing line of the first sheet product, a pseudo defect may be formed. have.

(Skipcut of another embodiment)

Moreover, another embodiment of the said 1st cutting process and a 2nd cutting process is demonstrated below. This embodiment is especially effective when the first inspection step and the second inspection step are not provided. At one end of the width direction of the first and second roll raw materials, defect information (inspection area coordinates, types of defects, size, etc.) of the first and second sheet-shaped products is provided in predetermined pitch units (for example, 1000 mm). It may be provided as code information (for example, a QR code and a barcode). In this case, in the first step of cutting, the code information is read, interpreted, and cut to a predetermined size in the first and second cutting steps so as to avoid defects. In this case, the code information reading device and the analyzing device correspond to the defect detecting device.

(Embodiment 2)

Embodiment 2 of this invention is demonstrated below. The flowchart of the manufacturing method of the optical display unit of Embodiment 2 is shown in FIG. The structure of the manufacturing system of the optical display unit in Embodiment 2 is shown in FIG. Processes similar to those in the first embodiment will be omitted or simply explained.

The 1st roll raw material preparation process (FIG. 2, S1) and a conveyance process (FIG. 2, S2) are the same as that of Embodiment 1. FIG.

Release film removal process (FIG. 2, S23). The peeling apparatus 13 before the 1st inspection peels the release film F12 (H11 in FIG. 5) from the 1st sheet | seat product F1 conveyed. The detail of a peeling mechanism is mentioned later.

1st defect inspection process (FIG. 2, S24). The 1st defect inspection apparatus 14 inspects the fault of the 1st sheet | seat product F1 (substantially 1st optical film F11 and 1st adhesive layer F14) after a release film removal process. It is not necessary to consider the phase difference inherent in the release film F12, and the fault inspection of the 1st optical film F11 and the 1st adhesive layer F14 can be performed. The defect inspection method is as described above. The optical films (1st optical film F11 and 1st adhesive layer F14) which have a 1st adhesive containing a fault are excluded by the 1st exclusion apparatus 19 mentioned later, and it is in liquid crystal panel W It is configured not to be attached.

Release film bonding process (FIG. 2, S25). The 1st release film bonding apparatus 15 bonds release film F12a (refer FIG. 5) to 1st optical film F11 through 1st adhesive layer F14 after a 1st fault inspection process. The detail of the 1st release film bonding apparatus 15 is mentioned later.

1st cutting process (FIG. 2, S26). Subsequently, after the release film bonding step, the first cutting device 16 leaves the release film F12a, and the surface protection film F13, the pressure-sensitive adhesive layer F15, the first optical film F11 and the first member of the other member. 1 The adhesive layer F14 is cut | disconnected to predetermined size.

1st bonding process (FIG. 2, S27). Then, after the 1st cutting process, the 1st peeling apparatus 17 peels off the release film F12a. The 1st bonding apparatus 18 is the optical film (including surface protection film F13 and adhesive layer F15) which has a 1st adhesive after the release film H12 peeled, The 1st adhesive layer F14 By bonding to the liquid crystal panel (W). At the time of bonding, as mentioned later, the optical film and liquid crystal panel W which have a 1st adhesive agent are clamped in a roll.

2nd roll raw material preparation process (FIG. 2, S11) and a conveyance process (FIG. 2, S12) are the same as that of Embodiment 1. FIG.

Release film removal process (FIG. 2, S33). The peeling apparatus 23 before a 2nd inspection peels the release film F22 (H21 in FIG. 7) from the 2nd sheet product F2 conveyed. The detail of a peeling mechanism is mentioned later.

2nd defect inspection process (FIG. 2, S34). After the release film removal step, the second defect inspection device 24 inspects the defects of the second sheet product F2 (substantially the second optical film F21 and the second pressure sensitive adhesive layer F24). Defects of the second optical film F21 and the second pressure-sensitive adhesive layer F24 without having to consider defects such as retardation inherent in the release film F22 and foreign matters or scratches attached or inherent in the release film F22. Inspection can be done. The method of defect inspection is as mentioned above. The optical films (2nd optical film F21 and 2nd adhesive layer F24) which have a 2nd adhesive containing a fault are excluded by the 2nd exclusion apparatus 29 mentioned later, and are attached to liquid crystal panel W1. It is configured not to be attached.

Release film bonding process (FIG. 2, S35). The 2nd release film bonding apparatus 25 bonds release film F22a (refer FIG. 7) to 2nd optical film F21 via the 2nd adhesive layer F24 after a 2nd fault inspection process. The detail of the 2nd release film bonding apparatus 25 is mentioned later.

2nd cutting process (FIG. 2, S36). Subsequently, after the release film bonding step, the second cutting device 26 leaves the release film F22a, and the surface protection film F23, the pressure-sensitive adhesive layer F25, the second optical film F21 and the second member of the other member. 2 The adhesive layer F24 is cut | disconnected to predetermined size.

2nd bonding process (FIG. 2, S37). Then, after the 2nd cutting process, the 2nd peeling apparatus 27 peels off the release film F22a. The 2nd bonding apparatus 28 uses the optical film (including surface protection film F23 and the adhesive layer F25) which has a 2nd adhesive from which the release film F22a peeled, The 2nd adhesive layer F24 It bonds to the surface from which the 1st optical film F11 of liquid crystal panel W1 is bonded by the other. By the above, the optical film which has a 1st adhesive on one surface of liquid crystal panel W, the optical film which has a 2nd adhesive on the other surface is bonded, and manufactures liquid crystal panel W12 in which the optical film was formed in both surfaces. can do.

(Suitable Manufacturing System for Realizing Manufacturing Methods of Embodiments 1 and 2)

Below, an example of the suitable manufacturing system which implements the manufacturing method of Embodiment 2 is demonstrated. FIG. 5: shows about the 1st conveying apparatus 12, the 1st pre-peeling apparatus 13, the 1st fault inspection apparatus 14, the 1st release film attachment apparatus 15, and the 1st cutting device 16. FIG. It is a figure.

FIG. 6: is a figure which shows about the 1st peeling apparatus 17, the 1st attachment apparatus 18, and the 1st exclusion apparatus 19. FIG. FIG. 7: About the 2nd conveying apparatus 22, the 2nd pre-peeling apparatus 23, the 2nd fault inspection apparatus 24, the 2nd release film attachment apparatus 25, and the 2nd cutting device 26. FIG. It is a figure which shows. FIG. 8: is a figure which shows about the 2nd peeling apparatus 27, the 2nd attachment apparatus 28, and the 2nd exclusion apparatus 29. As shown in FIG.

The various devices described above are isolated from the outside by the isolation structure 50. The inside surrounded by the isolation structure 50 is kept clean compared to the outside. The isolation structure 50 consists of a wall of frame material and a frame structure. The blower 40 is installed in the ceiling of the isolation structure 50. The blower 40 is equipped with a HEPA filter, and blows high clean air into the partition structure 50. An air discharge opening 50a for discharging internal air to the outside is provided in the lower wall surface of the partition structure 50. Moreover, in order to prevent the invasion from the outside, a filter may be provided in an opening surface. By this partition structure 50 and the blower 40, the whole manufacturing system can be maintained in a clean environment, and the foreign material mixing from the outside can be prevented appropriately. Moreover, since only a manufacturing system is isolate | separated from the exterior by the partition structure 50, it is not necessary to make a whole plant a so-called clean room.

The abrasive cleaning apparatus 10 can remove and clean the foreign matter on the surface by polishing both surfaces of the liquid crystal panel W with polishing means (not shown). Examples of the adherent foreign matter include glass microfibers, fiber fragments, and the like. The water washing | cleaning apparatus 11 is a structure which water-washes both surfaces of the liquid crystal panel W using a brush, and then surface-drys.

Next, FIGS. 5 to 8 will be described in order. The first roll raw material of the elongate first sheet product F1 is installed in a roller mount device linked to a motor or the like so as to rotate freely or at a constant rotational speed. The rotation speed is set by the control apparatus 1, and drive control is carried out.

The 1st conveying apparatus 12 is a conveying mechanism which conveys the 1st sheet | seat product F1 to a downstream side. The 1st conveyance apparatus 12 is controlled by the control apparatus 1.

The peeling apparatus 13 before a 1st inspection is a structure which peels the release film F12 from the 1st sheet | seat product F1 conveyed, and winds up to the roll 132. As shown in FIG. The winding speed to the roll 132 is controlled by the control apparatus 1. As the peeling mechanism 131, it has a knife edge part which has a sharp tip, peels off the release film F12, and peels off the release film F12 by winding the release film F12 at the knife edge part, and inverting and conveying it. It is comprised so that the 1st sheet | seat product F1 after doing may be conveyed to a conveyance direction.

The 1st defect inspection apparatus 14 carries out a defect inspection after peeling of the release film F12. The 1st defect inspection apparatus 14 analyzes the image data picked up by a CCD camera, detects a fault or pseudo fault, and calculates the position coordinate. The position coordinates of this fault are provided to the skip cut by the 1st cutting device 16 mentioned later. The structure of the defect detection by the 1st defect inspection apparatus 14 is as above-mentioned.

The 1st release film bonding apparatus 15 bonds release film F12a to 1st optical film F11 newly through 1st adhesive layer F14 after a 1st fault test. As shown in FIG. 5, the release film F12a is released from the roll raw material 151 of the release film F12a, and the release film F12a and the first optical film are formed by one or a plurality of roller pairs 152. (F11) is sandwiched and a predetermined pressure is applied to the roller pair 152 to join. The rotational speed, pressure control, and conveyance control of the roller pair 152 are controlled by the control device 1.

After bonding the release film F12a, the 1st cutting device 16 leaves the said release film F12a, and the surface protection film 15 of the other member, the 1st optical film F11, and the 1st adhesive layer ( F14) and the adhesive layer F15 are half-cut to predetermined size. The cutting timing can illustrate a configuration commanded from the control device 1 as described above. The cutting timing can be configured by the control means of the first cutting device 16. In this case, the defect information is transmitted to the first cutting device 16. The first cutting device 16 half-cuts the first sheet product F1 to a predetermined size a to avoid defect portions (including pseudo defects). That is, the cut | disconnected article containing a fault part is excluded by the 1st exclusion apparatus 19 in a post process as a defective article. Or the 1st cutting device 16 may cut | disconnect to predetermined size continuously, ignoring the presence of a fault. In this case, in the joining process mentioned later, it can comprise so that the said part may be removed without joining. Control in this case also depends on the function of the control apparatus 1.

Moreover, the 1st cutting device 16 arrange | positions the holding table which adsorbs-holds the 1st sheet product F1 from the back surface, and equips the laser apparatus above the 1st sheet product F1. It moves in parallel so as to scan a laser in the width direction of the 1st sheet product F1, and leaves the lowermost release film F12a, and the 1st adhesive layer F14, the 1st optical film F11, and a surface protection film ( F13) and the adhesive layer F15 are half-cut to predetermined | prescribed pitch in the conveyance direction. Moreover, this laser apparatus collects the air nozzle which injects a warm air toward a cut | disconnected part so that it may pinch from the width direction of the 1st sheet | seat product F1, and the gas (smoke) generated from the cut | disconnected site conveyed by this warm air. It is preferable that the swallowing is integrally formed in a state where the collecting duct is opposed to each other. In the case where the first sheet product F1 is adsorbed by the holding table, the accumulating device A of the conveying mechanism is not stopped so that continuous conveyance of the first sheet product F1 on the downstream side and the upstream side is not stopped. It is configured to move in the vertical direction. This operation is also controlled by the control device 1.

The 1st bonding apparatus 18 is an optical film (1st optical film F11, 1st adhesive layer) which has a 1st adhesive which the release film F12a peeled by the 1st peeling apparatus 17 after the said cutting process. At least (F14)] is bonded to the liquid crystal panel W by the first pressure sensitive adhesive layer F14.

As shown in FIG. 6, in the case of bonding, the optical film having the first pressure-sensitive adhesive is bonded to the liquid crystal panel W surface by the pressing roller 181 and the guide roller 182. The pressing pressure and the driving operation of the pressing roller 181 and the guide roller 182 are controlled by the control device 1.

As the peeling mechanism 171 of the 1st peeling apparatus 17, it has a sharp edge of a knife edge part, peels and releases the release film F12a by winding the mold release film F12a to the knife edge part, and inverting and conveying. It is comprised so that the 1st optical film F11 after peeling release film F12a may be sent to liquid crystal panel W surface. At this time, 100 N / m or more and 1000 N / m or less tension were applied to the release film F12a, and / or the first optical film F11 was pressed against the surface of the liquid crystal panel W after the release film F12a was peeled off. By carrying out the time until 3 seconds or less, the bonding precision of the 1st optical film F11 can be improved. If the tension is less than 100 N / m, the dispensing position of the first optical film is not stabilized. If the tension is greater than 1000 N / m, the release film F12a may be elongated and fractured. There exists a possibility that the edge part of the 1st optical film peeled from release film F12a may be bent, and bending and foaming may arise. The peeled release film F12a is wound up by the roll 172. Winding control of the roll 172 is controlled by the control apparatus 1.

As a joining mechanism, it consists of the press roller 181 and the guide roller 182 arrange | positioned facing it. The guide roller 182 is comprised by the elastic roller which rotates and drives by a motor, and is arrange | positioned so that lifting is possible. Further, immediately above, a pressing roller 181 constituted by an elastic roller that is rotationally driven by a motor is disposed so as to be liftable. When sending the liquid crystal panel W to the bonding position, the pressing roller 181 is raised to a position higher than the upper surface thereof to form a roller gap. In addition, both the guide roller 182 and the press roller 181 may be a rubber roller or a metal roller. As described above, the liquid crystal panel W is washed by various washing apparatuses and is conveyed by the transfer mechanism R. As shown in FIG. The conveyance control of the conveyance mechanism R also depends on the control of the control apparatus 1.

The 1st exclusion apparatus 19 which excludes the 1st sheet | seat product F1 containing a fault is demonstrated. When the 1st sheet product F1 containing a fault is conveyed to a joining position, the guide roller 182 will move vertically downward. Subsequently, the roller 192 over which the adhesive tape 191 is moved moves to the correct position of the guide roller 182. The pressing roller 181 is moved vertically downward, and the surface of the optical film (including the surface protective film F13 and the pressure-sensitive adhesive layer F15) having the first pressure-sensitive adhesive containing the defect is pressed with the adhesive tape 191. Thus, the optical film having the first pressure sensitive adhesive is attached to the adhesive tape 191, and the optical film having the first pressure sensitive adhesive including the defect is wound on the roller 193 together with the adhesive tape 191.

Liquid crystal panel W1 manufactured above is conveyed downstream, and the 2nd optical film F21 is bonded. In the following, the same apparatus configuration is demonstrated easily.

When bonding 2nd optical film F21 with 1st optical film F11 in 90 degree relationship (cross nicol relationship), liquid crystal panel W1 is conveyed by the conveyance direction switching mechanism of conveyance mechanism R. In FIG. After rotating 90 °, the second optical film F21 is bonded. In the bonding method of the 2nd sheet product F2 demonstrated below, each process is processed in the state which inverted the 2nd sheet product F2 (so that a release film might become an upper surface), and the 2nd optical film F21 ) Is bonded to each other from below the liquid crystal panel W1.

As shown in FIG. 7, the second conveying apparatus 22 is a conveying mechanism for conveying the second sheet product F2 to the downstream side. The 2nd conveyance apparatus 22 is controlled by the control apparatus 1.

The peeling apparatus 23 before a 2nd inspection is a structure which peels the release film F22 from the 2nd sheet product F2 conveyed, and winds up to the roll 232. The winding speed to the roll 232 is controlled by the control apparatus 1. As the peeling mechanism 231, the tip has a sharp knife edge portion, and the release film F22 is peeled off and the release film F22 is peeled off while the release film F22 is wound around the knife edge portion and transported in reverse. It is comprised so that the 2nd sheet product F2 of the after may be conveyed in a conveyance direction.

The 2nd defect inspection apparatus 24 carries out a defect inspection after peeling of the release film F22. The second defect inspection apparatus 24 analyzes the image data picked up by the CCD camera, detects the defect, and calculates the position coordinates. The position coordinates of this fault are provided to the skip cut by the 2nd cutting device 26 mentioned later.

The second release film bonding apparatus 25 bonds the release film F22a to the second optical film F21 through the second pressure sensitive adhesive layer F24 after the second defect inspection. As shown in FIG. 7, the release film F22a is released from the roll raw material 251 of the release film F22a, and the release film F22a and the second optical film are formed by one or a plurality of roller pairs 252. (F21) is sandwiched and a predetermined pressure is applied to the roller pair 252 for bonding. The rotational speed, pressure control, and conveyance control of the roller pair 252 are controlled by the control device 1.

After bonding the release film F22a, the 2nd cutting device 26 leaves the said release film F22a, and the surface protection film F23 of the other member, the adhesive layer F25, and the 2nd optical film F21. The second pressure sensitive adhesive layer F24 is half cut to a predetermined size. The second cutting device 26 is, for example, a laser device. Based on the positional coordinates of the defect detected in the second defect inspection process, the second cutting device 26 cuts to a predetermined size to avoid the defect portion. That is, the cut | disconnected article containing a fault part is excluded by the 2nd exclusion apparatus 29 in a post process as a defective article. Alternatively, the second cutting device 26 may be cut to a predetermined size continuously, ignoring the existence of the defect. In this case, in the joining process mentioned later, it can comprise so that the said part may be removed without joining. Control in this case also depends on the function of the control apparatus 1.

Moreover, the 2nd cutting device 26 arrange | positions the holding table which adsorbs-holds the 2nd sheet product F2 from the back surface, and equips the laser apparatus below the 2nd sheet product F2. It moves in parallel so as to scan a laser in the width direction of the 2nd sheet product F2, and leaves the lowermost release film F22a, and the surface protection film F23, the adhesive layer F25, and the 2nd optical film F21. , 2nd adhesive layer F24 is cut | disconnected by the predetermined pitch in the conveyance direction. In the case where the second sheet product F2 is adsorbed by the holding table, the accumulating device A of the conveying mechanism is so as not to stop the continuous conveyance of the second sheet product F2 on the downstream side and the upstream side. It is configured to move in the vertical direction. This operation is also controlled by the control device 1.

The 2nd bonding apparatus 28 is an optical film (surface protection film F23, adhesive layer F25) which has a 2nd adhesive with which the release film F22a peeled by the 2nd peeling apparatus 27 after a cutting process. Containing] is bonded to liquid crystal panel W1 by the 2nd adhesive layer F24. As shown in FIG. 8, when bonding, the optical film which has a 2nd adhesive agent is bonded together by the pressure roller 281 and the guide roller 282, making it press-contact with the liquid crystal panel W1 surface. The pressing pressure and driving operation of the pressing roller 281 and the guide roller 282 are controlled by the control device 1.

The structure of the 2nd peeling apparatus 27 and the 2nd bonding apparatus 28 is a functional structure similar to the 1st peeling apparatus 17 and the 1st bonding apparatus 18 mentioned above.

The 2nd exclusion apparatus 29 which excludes the 2nd sheet | seat product F2 containing a fault is demonstrated. When the 2nd sheet product F2 containing a fault is conveyed to a bonding position, the guide roller 282 will move vertically upward. Then, the roller 292 on which the adhesive tape 291 spreads moves to the correct position of the guide roller 282. The press roller 281 is moved vertically upward, and the optical film (including surface protection film F23 and adhesive layer F25) which has a 2nd adhesive containing a fault is pressed to the adhesive tape 291, The optical film which has a 2nd adhesive is attached to the adhesive tape 291, and the optical film which has a 2nd adhesive containing a fault with the adhesive tape 291 is wound on the roller 293.

Liquid crystal panel W12 in which the 1st, 2nd optical films F11 and F21 were formed is conveyed to the test | inspection apparatus 30. FIG. The inspection apparatus 30 performs inspection on both surfaces of the liquid crystal panel W12 which has been conveyed. The inspection contents are foreign matter on the surface of the optical film, contamination, foreign matter inside the laminated film, bubbles, breakage, contamination, and the like, and are composed of known reflection inspection means, transmission inspection means and the like.

The operation timing of each device is calculated by, for example, arranging and detecting a sensor at a predetermined position, or to detect the rotating members of the conveying devices 12 and 22 or the conveying mechanism R with a rotary encoder or the like. Is calculated.

In the above manufacturing system, it is the structure which attaches the optical film which has a 1st adhesive from the upper surface of liquid crystal panel W, and attaches the optical film which has a 2nd adhesive from the lower surface of liquid crystal panel W. FIG. It is not limited to this attachment structure, The structure which attaches the optical film which has a 1st adhesive from the lower surface of liquid crystal panel W, and then attaches the optical film which has a 2nd adhesive to the upper surface of liquid crystal panel W is carried out. It is possible.

(Other embodiment of defect inspection method)

An automatic inspection device that realizes defect inspection is an apparatus for automatically inspecting defects (also called defects) of sheet-shaped products, and irradiates light, and captures the reflected or transmitted images by a line sensor or a two-dimensional TV camera. It acquires through a part and detects a fault based on the acquired image data. Moreover, image data is acquired in the state which interposed the inspection polarizing film in the optical path between a light source and an imaging part. Usually, the polarization axis (for example, polarization absorption axis) of this inspection polarizing film is arrange | positioned so that it may be in the state (cross nicol) orthogonal to the polarization axis (for example, polarization absorption axis) of the polarizer of the sheet | seat product used as an inspection object. By arranging with cross nicol, for example, when a defect is not present, a front black image is input from the image pickup unit, but if a defect is present, the portion is not black (recognized as a bright point). Therefore, a defect can be detected by setting an appropriate threshold value. In such bright spot detection, defects such as surface deposits and foreign matter inside are detected as bright spots. In addition to this bright spot detection, there is also a method of detecting foreign matter by CCD imaging an image of a transmitted light on an inspection object and analyzing the image. There is also a method of detecting foreign matter on the surface by CCD imaging the reflected light image with respect to the inspection object and analyzing the image.

In the said cutting process, although the half cut system which cuts the other member of a sheet | seat product leaving a mold release film was demonstrated, the cutting process of this invention is not limited to the cutting system. In addition, although the bonding method by a roll pair was demonstrated in the bonding process of bonding a sheet | seat product to an optical display substrate after cutting | disconnection, the bonding process of this invention is not limited to the system.

(adhesive)

Although the said adhesive layer is not specifically limited, It can form with the appropriate adhesive according to the prior art, such as an acryl type. The moisture absorption rate is low and heat resistance is due to the prevention of foaming or peeling phenomenon due to moisture absorption, reduction of optical properties due to thermal expansion difference, prevention of warpage of liquid crystal cells, and furthermore, formation of an image display device having high quality and durability. It is preferable that it is this excellent adhesion layer. Moreover, it can be set as the adhesion layer etc. which contain microparticles | fine-particles and show light diffusivity. What is necessary is just to form an adhesion layer in a required surface as needed, for example, when it mentions the polarizing plate which consists of a polarizer and a polarizer protective layer, what is necessary is just to form an adhesion layer on one side or both surfaces of a polarizer protective layer as needed.

(Release film)

As said release film, suitable thin films, such as various plastic films, a rubber sheet, paper, a cloth, a nonwoven fabric, a net, a foam sheet, a metal foil, and those laminates, are silicone type | system | group, long-chain alkyl type, fluorine type, as needed, for example. Suitable ones according to the prior art, such as those coated with an appropriate release agent such as molybdenum sulfide, can be used.

(Surface protection film)

As a surface protection film, suitable thin films, such as various plastic films, a rubber sheet, paper, cloth, a nonwoven fabric, a net, a foam sheet, a metal foil, and those laminates, are silicone type | system | group, long-chain alkyl type, fluorine type, and sulfide as needed, for example. Suitable ones according to the prior art, such as those coated with an appropriate release agent such as molybdenum, can be used.

The optical display unit by this invention can be used suitably for formation of image display apparatuses, such as a liquid crystal display device, an organic electroluminescence display, and a PDP.

F1: first sheet product
F2: second sheet product
F11: first optical film
F11a: first polarizer
F11b: first film
F11c: second film
F12: first release film
F13: surface protective film
F14: 1st adhesive layer
F21: second optical film
F21a: second polarizer
F21b: third film
F21c: fourth film
F22: second release film
F23: surface protection film
F24: second pressure sensitive adhesive layer
W: liquid crystal panel (optical display substrate)
1: control device
10: abrasive cleaning device
11: water washing device
12: first conveying device
13: peeling device before the first inspection
14: first defect inspection device
15: first release film bonding apparatus
16: first cutting device
17: first peeling apparatus
18: first bonding device
19: first exclusion device
22: second conveying device
23: peeling device before the second inspection
24: second defect inspection device
25: second release film bonding apparatus
26: second cutting device
27: second peeling apparatus
28: second bonding device
29: second exclusion device
201: marking device
202: imaging means
203: pseudo defect detection means
204: location information determining means
205: cutting position correction means
301: image analysis means
302: encoder
303: memory
304: comparison means
305: correction means
306: conveyance control means
307: measured conveying distance calculating means
308: prediction carrier distance calculation means

Claims (17)

  1. The long sheet product which the release film was bonded to the optical film through the adhesive layer is cut | disconnected to a predetermined shape leaving the said release film by a cutting means, and the optical which has the adhesive of the adhesive layer and optical film of the predetermined shape obtained by this cutting | disconnection is obtained. It is a method of peeling a film piece from the said release film, bonding to an optical display board | substrate from the adhesive layer side, and manufacturing an optical display unit,
    In the process of conveying the said sheet product, the estimated conveyance distance at the time of conveying position specifying information formed in the said sheet product from the 1st position of a conveyance upstream to the 2nd position of a conveyance downstream rather than the said 1st position, and the said The said 1st position measured by the conveyance distance measuring means which detects the said position specification information using a detection means in each of a 1st position and the said 2nd position, and measures the conveyance distance of the said sheet product based on the said detection result. From the measured conveyance distance between the said 2nd position,
    The said conveyance distance measuring means is correct | amended so that the said measured conveyance distance may be in a predetermined range on the basis of the value of the said predicted conveyance distance, The manufacturing method of the optical display unit characterized by the above-mentioned.
  2. The manufacturing method of the optical display unit according to claim 1, wherein the predicted conveyance distance is set based on an experience value of test operation or actual operation.
  3. The manufacturing method of the optical display unit of Claim 1 or 2 in which the detection means in the said 2nd position is provided in the conveyance direction downstream or upstream of the said cutting means.
  4. The manufacturing method of the optical display unit of Claim 1 or 2 in which the said position specifying information is previously formed in the said sheet product, and the said sheet product is wound in roll shape.
  5. The manufacturing method of the optical display unit of Claim 1 or 2 which forms the said position specifying information in the said sheet product from the conveyance upstream rather than the said 1st position.
  6. The manufacturing method of the optical display unit of Claim 1 or 2 which notifies that the said measured conveyance distance is not in the predetermined range of the said predicted conveyance distance.
  7. The said sheet product contains the fault which is inherent in the said adhesive layer, the said optical film, or both, and cut | disconnects to the optical film piece which has the said adhesive of the said predetermined shape which excluded the said fault. The manufacturing method of an optical display unit.
  8. The release film is peeled from the sheet product before the first position, and defect inspection of the optical film and the pressure-sensitive adhesive layer is carried out, and after the defect inspection, the release film is applied to the pressure-sensitive adhesive layer. The manufacturing method of the optical display unit to bond.
  9. The optical film piece which has the adhesive which consists of a pressure-sensitive adhesive layer and an optical film of the predetermined shape obtained by cutting | disconnecting the long sheet | seat product which the release film was bonded to the optical film through the adhesive layer, leaving the said release film, and cut | disconnecting the said, It is a system which peels from the said release film and bonds to an optical display board | substrate at the adhesive layer side, and manufactures an optical display unit,
    Conveying means for conveying the sheet product;
    Conveyance control means for controlling the conveying means;
    Conveying distance measuring means for measuring a conveying distance of said sheet product,
    In the process of conveying the said sheet product, the estimated conveyance distance at the time of conveying position specifying information formed in the said sheet product from the 1st position of a conveyance upstream to the 2nd position of a conveyance downstream rather than the said 1st position, and the said The said position specifying information is detected using a detection means in each of a 1st position and the said 2nd position, and the actual measurement between the said 1st position and the said 2nd position measured with the said conveyance distance measuring means based on the said detection result. Comparison means for comparing the conveying distance,
    Correction means for correcting the conveying distance measuring means such that the measured conveying distance is within a predetermined range based on the value of the predicted conveying distance;
    Cutting means for cutting the sheet product into an optical film piece having an adhesive of the predetermined shape;
    Peeling means which peels the optical film piece which has the said adhesive from a release film,
    The manufacturing system of the optical display unit which has the bonding means which bonds the optical film piece which has the said adhesive with the said release film peeled to an optical display board | substrate from the adhesive layer side.
  10. The manufacturing system of the optical display unit according to claim 9, wherein the predicted conveyance distance is set based on an experience value of test operation or actual operation.
  11. The manufacturing system of the optical display unit of Claim 9 or 10 in which the detection means in the said 2nd position is provided in the conveyance direction downstream or upstream of the said cutting means.
  12. The manufacturing system of the optical display unit of Claim 9 or 10 which has position specification information formation means which forms the said position specification information in the said sheet product from a conveyance upstream rather than the said 1st position.
  13. The manufacturing system of the optical display unit of Claim 9 or 10 which has a notification means which notifies that the said measured conveyance distance is not in the predetermined range of the said predicted conveyance distance.
  14. The said sheet product contains the fault which is inherent in the said adhesive layer, the said optical film, or both, and cut | disconnects into the optical film piece which has the said adhesive of the said predetermined shape which excluded the said fault. Manufacturing system of the optical display unit.
  15. The peeling means of Claim 9 or 10 which peels a mold release film from the said sheet product before a said 1st position,
    Means for inspecting defects of the optical film and the pressure-sensitive adhesive layer after the release film is peeled off;
    And a bonding means for bonding a release film to the pressure-sensitive adhesive layer after the defect inspection.
  16. delete
  17. delete
KR1020107019091A 2008-01-29 2009-01-27 Manufacturing Method of Optical Display Unit and Manufacturing System of Optical Display Unit KR101051868B1 (en)

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JP2009010704A JP4737569B2 (en) 2008-01-29 2009-01-21 Optical display unit manufacturing method and optical display unit manufacturing system
JPJP-P-2009-010704 2009-01-21
PCT/JP2009/051264 WO2009096388A1 (en) 2008-01-29 2009-01-27 Method of manufacturing optical display unit and manufacturing system of optical display unit

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CN101925944B (en) 2013-07-10
TWI354956B (en) 2011-12-21
KR20100117089A (en) 2010-11-02
EP2244244A1 (en) 2010-10-27
JP4737569B2 (en) 2011-08-03
US20100294418A1 (en) 2010-11-25
TW200947375A (en) 2009-11-16
JP2009205145A (en) 2009-09-10
CN101925944A (en) 2010-12-22
WO2009096388A1 (en) 2009-08-06

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